Malaguti MADISON 3 125 cc Workshop Manual

MADISON 125 cc. - Euro 3

B

TROUBLESHOOTING

ELECTRICAL SYSTEM

WORKSHOP MANUAL

2 08.06

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MADISON 125 cc

Introduction

CHAPTER

PAGE ISSUE

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X

Y

Z W

J

INTRODUCTION

- This publication describes all necessary steps for troubleshooting concerning the electrical system and

the possible service operations, which are necessary for their solution. It supplies the trade technicians

(Authorised Service Centres) with the necessary information for operating in compliance with the modern concepts

of “good practice” and “safety at work”.

- Further information can be derived from the “Chassis” Workshop Manual - from the “Engine” Workshop

Manual - from the Spare Parts Catalogue.

- All described operations must be performed by technicians with the necessary skill and experience.

- The steps for removal of body parts and of electrical and mechanical components, to allow access to wiring or

electric components to service, can be taken from the “Chassis” Workshop Manual.

- We recommend you follow the information given in this publication with care.

- For any further information you may need, refer to the Malaguti S.p.A. Technical Department.

- It is essential to follow the instructions with great care. Work carried out carelessly or, worse still, work that

has not been accomplished, can cause injuries and damage or, in the less serious cases, tiresome complaints.

NOTES FOR EASY CONSULTATION

PAGE LAYOUT

X

Y Chapter

X Motor vehicle model

J Section

W Page N

Z Date of issue

ABBREVIATIONS

F. Figure

Pag. Page

Pr Paragraph

S Section

Sch Diagram

T Table

MODIFIED PAGES

- Modified pages shall bear the same number as those in the previous edition, followed by the letter M, with the

new date of issue appearing in the appropriate box.

- Modified pages may contain new illustrations; in this case, the added illustration (or illustrations) will bear the

number of the former illustration, followed by a letter.

- Negative illustration numbers (such as for instance F. 5 ) mean that the previous numbers have been

intentionally omitted.

ADDITIONAL PAGES

- Any additional pages shall bear the last number of the section to which they belong, followed by the letter A and

the new date of issue.

08.06 3

MADISON 125 cc

Introduction

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CHAPTER

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ENGLISH

FIRST EDITION : 08/06

OPERATIONAL SYMBOLS

IMPORTANT!

CAUTION! - situations entailing the risk of personal injury to maintenance or repair mechanics, other

workshop personnel or third parties, or damage to environment, vehicle or equipment.

ENGINE OFF - operations to be informed with the engine off.

CUT OFF POWER - before performing the operation described, disconnect the battery negative.

MECHANICAL MAINTENANCE - operations to be performed only by an expert mechanic.

ELECTRICAL MAINTENANCE - operations to be performed only by an expert electrical/electronic

technician.

NO! - Operations to be absolutely avoided.

WARNINGS

- Before any servicing, make sure that the vehicle is perfectly stable.

The front wheel should preferably be anchored to the equipment integral with the lifting board.

- For checks and calibration, use tools of an ascertained quality and never empirical means or tools with a

limited reliability.

- “Malaguti S.p.A.” declines all responsibility for damage of any kind caused by use of inadequate systems for

checking the electrical and electronic equipment.

- “Malaguti” reserves the right to make any and all changes to its vehicles as it deems fit and appropriate at any

time without prior notice.

- No part of this publication, whether text or illustrations, may be reproduced or circulated. “Malaguti”

reserves all rights over this publication. Reasons must be given for any request for permission (written) thereto.

4 08.06

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MADISON 125 cc

Introduction

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Table of contents

Page

Introduction 2

Checking Switches 6

Fuses 8

General Wiring Diagram 11

Ignition System 14

Charging System 16

Electrical Starting System 18

Light System 20

Signalling System 25

08.06 5

MADISON 125 cc

Introduction

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TECHNICAL TERM DICTIONARY

• Multimeter (Tester) (code n° 08609500)

• V = (DC): direct current (supply from battery)

• V ~ (AC): alternating current (supply from flywheel)

• A: Ampere = the unit of electric current

• W: Watt = the unit of electric power (result of Volts by Amps A x V = W)

•

::

:?: OHM = the unit of electrical resistance

• Infinite OHM = tester prods disconnected or cable interrupted

• OHM = 0: continuity with tester prods connected and cable not interrupted

• PIN: connector terminal

• Line: cable between two PINS

• < = less than

•



 = less than or equal to

• > = greater than

•



 = greater than or equal to

• KPa (o bar): the unit of pressure (100 KPa = 1 bar)

• ÷ = from - to

• ~ = approximately

6 08.06

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MADISON 125 cc

Checking Switches

CHAPTER

ENGLISH

CHECKING SWITCHES

CHECKING PROCEDURES

- Using a Tester (code n°08609500), check switches. In particular, check continuity between terminals to make

sure they are correctly connected.

- Replace the switch, even if only one of the possible combinations does not give the requested result.

Set the tester to function

::

:.

CONNECTION OF SWITCHES DESCRIBED IN THIS MANUAL

- This manual contains connection diagrams, like the one illustrated here below, which illustrate how switch

terminals should be connected (key switch, brake switch, “Mode” button, etc.).

- The first column from the left indicates the different positions of the switch, the top line the colour of the wires

connected to the switch terminals.

- The symbol identifies terminals in which there is a condition of continuity, i.e. a closed circuit, in a certain

position of the switch.

- In this diagram:

- “B/R” and “N”: there is continuous contact when the switch is “ON”.

F. 1

F. 2

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MADISON 125 cc

Checking Switches

B

CHAPTER

ENGLISH

9

10

11

3

2

1

6

7

8

1

4

3

2

5

6

7

8

9

10

11

12

13

B-GR

R

ON

0FF

LO

HI

AZ-B

GL-N

B-N

AR

N

B-GR

R

0FF

ON

0FF

GL-N

RS

BL

B-R

N

GL-BL

GL-B

B-BL

R

OFF

ON

BL-N

VR-N

N

BL

GL-B

BL-R

13

12

N

5

4

ON

0FF

R

L

BL

B-N

M

VL

VR

POSITION OF SWITCHES AND CONNECTION OF CONNECTORS

1) Rear stop switch 8) Engine start switch

2) Horn control 9) Engine stop switch

3) Light switch 10) Mode

4) Passing 11) Key switch

5) Turn indicator switch 12) Side stand switch

6) Front stop switch 13) Fuse carrier

7) Main light switch

NOTE: the start switch is closed when the START button is pressed.

The side stand switch is closed when the stand is idle.

The STOP switch is closed when the brake lever is operated.

8 08.06

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MADISON 125 cc

Fuses

CHAPTER

ENGLISH

F. 3

FUSES

CHECKING FUSES

CAUTION: when checking fuses, always turn the main switch “OFF” or short-circuits may occur.

Checking procedure:

- Connect Tester (code n°08609500) to fuse and check continuity.

NOTE: put the Tester on “

::

:” (sound-emitting function).

- If the tester is showing “I” and no sound is given, replace the fuse.

Replacing procedure:

- Turn key “OFF”.

- Fit a new fuse with a correct amperage rating.

- Turn key “ON”.

- Turn switches on to check operation of the relative electrical systems.

- If the fuse blows again, check the relative circuit.

CAUTION: never use fuses with an amperage differing from that indicated. Use only fuses and never

other materials.

An unsuitable fuse can cause extensive damage to the electrical system, malfunctioning of the ignition

and light systems and even fires to break out.

08.06 9

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MADISON 125 cc

Fuses

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CHAPTER

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1 2 3 4 5 6 7 8

FUSES

The electrical equipment includes 10 fuses.

Before replacing a fuse, locate and eliminate the fault causing its interruption.

F. 4

F. 5

9) 30 A Recharge protection fuse

1) 15 A Lights

2) 7.5 A Turn indicators/stop

3) 3 A “ENGINE STOP”

4) 10 A Key

5) 30 A Main

6) - Not active

7) 7.5 A Radiator fan

8) 5 A 12 V Socket

10 08.06

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MADISON 125 cc

Fuses

CHAPTER

ENGLISH

CHECKING CONNECTORS

- Check connectors for corrosion and damp.

- Disconnect connectors.

- Dry terminals with compressed air.

- Connect and disconnect connector two or three times.

- Pull connector to make sure it is correctly plugged in.

- If terminal is disconnected, bend stop (A) and refit terminal in connector.

- Plug in connectors.

NOTE: the “click” sound means that all connector parts are correctly assembled.

- Check continuity with a Tester.

NOTE: if there is no continuity, clean terminals.

As a temporary solution, use a contact cleaner.

Follow the instructions above to check the electrical equipment.

Use Tester as shown in the illustration.

F. 6

F. 7

F. 9

F. 8

08.06 11

MADISON 125 cc

General Wiring Diagram

B

CHAPTER

ENGLISH

ISSUE PAGE

GENERAL WIRING DIAGRAM

FUSE 15 A

3A

N

FUSE 7.5 A

30 A

BLBL

M-NM-N

VR

VLVL

ARAR

N

GL-N

GL-NGL-N

BL

B-NB-N

B-N

VRVR

VLVL

N

R-VRR-VR

AZ-BAZ-B

M

VLVL

RSRS

R

N

VR

VLVL

R

N

VR

N

B

GL-BLGL-BL

R

BL

R-VR

GL-BGL-B

GL-NGL-N

BLBL

RSRS

B-RB-R

B-R

N

R

GR-RGR-R

BL-N

R

B-GRB-GR

R

B-BL

MODE

0FF0FF

ONON

ENGINE STOP

START

LIGHTS

N

R-B

GL-B

GL-BL

RSRS

BLBL

ONON

0FF0FF

N-RN-R

CONN

ETORE

CRUSC

OTTO

CONN

ET

ORE

CRUSC

OTT

O

ONON

0FF0FF

ONON

0FF0FF

R

LOLO

HIHI

LUCI

HORN

PASSING

R

L

TURN

B-GRB-GR

N

1

2

3

4

5

6

7

8

9

10

1111

1212

2424

2323

2222

2121

2020

1919

1818

1717

1616

1515

1414

1313

1

2

3

5

7

8

9

10

1111

1313

1515

1616

GL-BGL-B

N

B-VR

GRGR

VLVL

B-NB-N

GR-RGR-R

B

BL-R

B-VLB-VL

GL-BLGL-BL

BLBL

R-NR-N

RSRS

AZ-BAZ-B

VRVR

GL-RGL-R

N

B-N

N

B-N

AZ-BAZ-B

B-GRB-G

R

M-N

NODO MASSE ZONA

TELAIO REGOLATORE

NODO MASSE ZONA

TELAIO REGOLATORE

ARAR

BLBL

VLVL

N

VR

B

R

1616

W

35 w

35

w

35 w

35

w

35 w

35

w

35 w

35

w

5

W

N

RSRS

BLBL

B-NB-N

AZ-B

GL-NGL-N

B-N

VL

VRVR

M

AR

N

B-BLB-BL

GL-BGL-B

N

R

R.P.M

R

B

RSRS

N

RSRS

N

GL-NGL-N

OFFOFF

ONON

BAR - OILBAR - OIL

TEMPERATURA H2OTEMPERATURA H2O

LIVELLO CARBURANTELIVELLO CARBURANTE

5w

21w

5w

21w

5w

21w

5w

21w

10 W10

W

10 W

10

W

5W5W

2

W

Diodo 2ADiodo

2A

N

OpenOpen

CloseClose

RSRS

B-NB-N

AZ-BAZ-B

N

RSRS

B-NB-N

AZ-BAZ-B

N

VLVL

VRVR

BL-NBL-N

VR-NVR-N

N

BLBL

GL-BGL-B

BL-RBL-

R

BL

N

GL-B

BL-RBL-

R

VR-NVR-N

BL-NBL-N

BLBL

BL-RBL-R

GL-VLGL-VL

R-BLR-BL

BLBL

R-VRR-VR

B-GRB-GR

BL-N

GL-VLGL-VL

R

BL-R

GLGL

BLBL

AZ-GRAZ-GR

10 A

N

R-VRR-VR

N

GL

GRGR

N

GL-NGL-N

GL-BGL-B

N

CAVALLETTOCA

V

ALLETT

O

12V

12Ah

12V

12Ah

GRGR

N

<18 B<18

B

13B>13 B>

7B<7B<

N

RS

N

RS

>

1/4 W 1KS1/4

W

1KS

N

VLVL

VRVR

N

VLVL

N

VRVR

>

B-VRB-VR

4 5

6

7

8

3

GLGL

INTERRUTTORE

TERMICO VENTOLA

100º - 95º

020.023.00

INTERRUTT

ORE

TERMICO VENT

OLA

100

º-

95

º

020.023.00

B

N

VR

VRVR

B-VLB-VL

GL-RGL-R

M-BM-B

GL-RGL-R

M

AR

N

VR

ARAR

N

M

BLBL

GL-BGL-B

N

BAR - OILBAR

-

OIL

7.5 A

5A

M-BM-B

GL-B

N

B-RB-R

AZ-GRAZ-GR

AZ-GR

GL-NGL-N

<1B<1B

<19B<19B

<8B<8B

N

B

B-RB-R

AR-BLAR-BL

BLBL

R

M-BM-B

<

PICK UPPICK

UP

0241290002412900

3>3>

8>8>

7>7>

5>5>

6>6>

>

ENGINE STOP

ENGINE

ST

OP

MASSA AL

RADIATORE

MASSA

AL

RADIA

T

ORE

3030

3131

3232

3333

3434

3535

3636

2929

1

22

3

4

5

6

9

1010

1111

1212

1313

1414

1515

1616

1717

2020

2121

2222

2323

2424

2525

2828

2727

+12 DIRETTO BATTERIA

SOTTO CHIAVE

MODE

SONDA C/KM

SEGNALE SONDA C/KM

8

7

1818

1919

2626

CHASSIS MASS NODE

IN REGULATOR ZONE

12 08.06

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MADISON 125 cc

General Wiring Diagram

CHAPTER

PAGE ISSUE

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KEY TO GENERAL WIRING DIAGRAM

1) BATTERY

2) PROVISION FOR ANTI-THEFT SYSTEM

3) SWITCH WITH KEY

4) HORN

5) FLASHLIGHT

6) REAR LEFT STOP SWITCH

7) LEFT SWITCH

8) HEADLIGHTS

9) AMBIENT TEMPERATURE PROBE

10) INSTRUMENT BOARD

11) RIGHT SWITCH

12) REAR RIGHT STOP SWITCH

13) POWER SUPPLY SOCKET FOR RECHARGING (12 V)

14) ELECTRONIC CONTROL UNIT

15) ELECTRIC STARTER ON CARBURETTOR

16) COIL

17) WATER TEMPERATURE SENSOR

18) FUEL PROBE

19) VOLTAGE REGULATOR

20) FLYWHEEL

21) REV COUNTER SENSOR

22) SIDE STAND SWITCH

23) RADIATOR FAN

24) STARTER MOTOR

25) HELMET COMPARTMENT LIGHT

26) REAR LIGHTS

27) REMOTE SWITCH

28) REMOTE START SWITCH (BLACK)

29) FUSE, 30 A

30) FUSE, 5 A

31) FUSE, 7.5 A

32) FUSE, 30 A

33) FUSE, 10 A

34) FUSE, 3 A

35) FUSE, 7.5 A

36) FUSE, 15 A

08.06 13

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General Wiring Diagram

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1

23

4

5678

9

10 11 12

13

14

15 16

17

18 19

20

21 22 23 24

INSTRUMENT BOARD CONNECTOR CONFIGURATION

1)RPM 9) BATTERY POSITIVE 17)NEGATIVE

2)RIGHT TURN INDICATOR 10) - 18)FUEL PROBE

3)LOW BEAM LIGHTS 11) - 19)TEMPERATURE PROBE

4)PARKING LIGHTS 12) ENGINE STOP 20)-

5)AMBIENT TEMPERATURE 13) HALL SENSOR INPUT 21)-

6)POSITIVE WITH KEY ON 14) MODE BUTTON 22)-

7)HALL SENSOR V DC 15) HIGH BEAM LIGHTS 23)-

8)BAR-OIL 16) LEFT TURN INDICATOR 24)-

INSTRUMENT BOARD CONNECTOR

GENERAL WIRING DIAGRAM

COLOUR KEY

N-R BLACK/RED B-VL WHITE/PURPLE

R RED B-BL WHITE/BLUE

R-VR RED/GREEN B-GR WHITE/GREY

RS PINK BL BLUE

RS-N PINK/BLACK BL-N BLUE/BLACK

VL PURPLE BL-R BLUE/RED

VL-N PURPLE/BLACK BL-VR BLUE/GREEN

VR-N GREEN/BLACK GL YELLOW

VR GREEN GL-B YELLOW/WHITE

AR ORANGE GL-N YELLOW/BLACK

AR-B ORANGE/WHITE GL-V YELLOW/GREEN

AR-VR ORANGE/GREEN GL-R YELLOW/RED

AR-BL ORANGE/BLUE GL-BL YELLOW/BLUE

AZ LIGHT BLUE GR GREY

AZ-B LIGHT BLUE/WHITE GR-R GREY/RED

AZ-GR LIGHT BLUE/GREY M BROWN

B WHITE M-B BROWN/WHITE

B-VR WHITE/GREEN M-N BROWN/BLACK

B-N WHITE/BLACK N BLACK

B-R WHITE/RED

14 08.06

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MADISON 250 I.E.

Ignition System

CHAPTER

ENGLISH

2

0,6÷0,7 mm

F. 1 0

F. 11

1

IGNITION SYSTEM

TROUBLESHOOTING

1 SPARK PLUG IS NOT SPARKING. CHECK:

1. Spark plug

2. Spark plug cap resistance

3. HV coil

4. Pick-up resistance

5. Wiring connections

1.1 Spark plug

- Check condition of spark plug.

- Check type of spark plug.

- Check gap between electrodes: 0.6 ÷ 0.7 mm.

1.2 Spark plug cap resistance

- Remove spark plug cap.

NOTE: when removing spark plug cap, do not pull.

- To remove Turn anti-clockwise.

- To connect Turn clockwise.

- Before connecting the spark plug cap, check the HV cable and cut off a piece of approximately 5 mm.

- Connect Tester (K

::

:) to spark plug cap, as follows:

- Terminal (+) of Tester Spark plug side (1).

- Terminal (-) of Tester High voltage cable side (2).

- Spark plug cap resistance: 5 K

::

: at 20°C.

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Ignition System

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2

F. 1 2

F. 13

F. 1 4

R

1.3 HV coil

A) Primary winding resistance

- Connect tester (

::

:).

- Compliant: 0.6 ÷ 0.8

::

: at 20°C.

B) Secondary winding resistance

- Connect tester (K

::

:).

- Compliant: 2.50 ÷ 3.50 K

::

: at 20°C.

1.4 Check pick-up (flywheel)

- Remove wiring connector from flywheel cover.

- Connect Tester (

::

:) to connector on flywheel cover (R).

- Terminal (+) of Tester Connection n°2.

- Terminal (-) of Tester Chassis grounding.

- Resistance measured must be: 105 ÷ 124

::

: at 20°C

1.5 Cable connection

- Check connections of ignition system (refer to the wiring diagram), paying attention to the cable colours and to

how they are connected to the various connectors.

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MADISON 125 cc

Charging System

CHAPTER

ENGLISH

CHARGING SYSTEM

TROUBLESHOOTING

1 IF THE BATTERY CANNOT BE CHARGED, CHECK:

1. 30 A Fuse (helmet compartment)

2. Battery

3. Charging voltage

4. Stator coil resistance

5. Charging system wiring

1.1 30 A Fuse (helmet compartment)

- Remove relative fuse.

- Connect Tester (

::

:) to fuse.

- Check continuity of fuse.

- If fuse has blown: eliminate cause of short-circuit and replace fuse with an identical one.

F. 1 5

1.2 Battery

- Remove battery and connect Tester (20 V DC), as follows:

- Terminal (+) of Tester Battery (+) pole.

- Terminal (-) of Tester Battery (-) pole.

- If voltage level is lower than 12.4 V, recharge using a suitable battery charger.

- After charging the battery, do not use it for approximately 30 minutes, then measure voltage level again.

- 12.8 V or more Battery is charged.

- 12.5 V Battery needs to be recharged.

- 12.0 V Replace battery.

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Charging System

B

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+

-

12V

.

12V

.

F. 16

R

1

3

5

1.3 Checking charging voltage (use a charged battery)

- Connect Tester (20 V DC) to battery as follows:

- Terminal (+) of Tester Battery (+) pole.

- Terminal (-) of Tester Battery (-) pole.

- Run engine at approx. 5000 RPM.

- The voltage measured should be: 12.80 ÷ 14 V

1.4 Check stator recharging resistance

- Remove wiring connector from flywheel cover.

- Connect Tester (

::

:) to connector on flywheel cover (R).

- Make sure resistance measured between connections 3-5, 1-5 and 1-3 is 0.2 ÷ 0.8

::

:

NOTE: always check grounding isolation of three terminals.

F. 17

1.5 Checking wiring connections

- Check connections of the entire charging system.

- See “Wiring Diagram”.

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Electrical Starting System

CHAPTER

ENGLISH

+

-

N

12V

.

12V

.

N

F. 1 9

1.2 Battery

- Check condition of battery.

- See “Checking Battery” (page 16).

1.3 Check starter motor

- Using two cables, connect a 12 V battery to the starter motor and check if the latter is working.

F. 1 8

Tester

::

:)

ELECTRICAL STARTING SYSTEM

TROUBLESHOOTING

1 IF STARTER MOTOR DOES NOT WORK, CHECK:

1. 7.5 A fuse N° 2, 3 A fuse N° 3, 30 A fuse N° 5

2. Battery

3. Starter motor

4. Remote start switch / Remote start circuit interruption switch

5. Key switch

6. Engine stop switch

7. Side stand switch

8. Start switch (START)

9. Front/rear stop switch

10. Starting system wiring connections

1.1 7.5 A fuse N° 2, 3 A fuse N° 3, 30 A fuse N° 5

- Remove relative fuse.

- Connect Tester (

::

:) to fuse.

- Check continuity of fuse.

- If fuse has blown: eliminate cause of short-circuit and replace fuse with an identical one.

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MADISON 125 cc

Electrical Starting System

B

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1.4 Remote start switch (black connector - Code n°02502500) - Remote start circuit interruption switch

(white connector - 02504300)

- Detach remote switch connector.

- Connect Tester (

::

:) and a battery (12 V) to remote switch terminals, as follows:

- Battery (+) pole Terminal (86).

- Battery (-) pole Terminal (85).

WARNING: never invert battery connections on remote switch terminals.

- Terminal (+) of Tester Terminal (87).

- Terminal (-) of Tester Terminal (30).

- Check continuity.

+

-

N

12V

.

12V

.

85

30

86

87

F. 20

1.5 Key switch